System and process for friction consolidation fabrication of permanent magnets and other extrusion and non-extrusion structures

Patent metadata

Field	Value
Publication number	US-10109418-B2
Application number	US-201414268216-A
Country	US
Kind code	B2
Filing date	May 2, 2014
Priority date	May 3, 2013
Publication date	Oct 23, 2018
Grant date	Oct 23, 2018

Abstract

A die tool and process are described that provide friction consolidation fabrication and friction consolidation extrusion fabrication products including permanent magnets, and other extrusion and non-extrusion structures. The present invention overcomes previous particle size, texture, homogeneity and density limitations in conventional metallurgy processes.

First claim

What is claimed is:

1. A permanent magnet forming process, the process comprising the steps of:
compressing a hard magnetic material and a soft magnetic material together within a magnetic field while rotating both in at a rotation speed and temperature sufficient to homogenously mix and frictionally consolidate the hard and soft materials while exchange coupling the hard and soft magnetic materials together within the magnetic field; and
cooling the consolidated magnetic material in a magnetic field to align grains of the exchange coupled materials along a selected axis therein.

2. The process of claim 1 further including the step of extruding the cooled consolidated magnetic material to form permanent magnet structures with selected shapes prior to cooling same.

3. The process of claim 1 further comprising the step of adding a grain size controlling agent to the hard and soft materials prior to compression and rotation, the agent selected from the group consisting of Cu, Nb, Y, TiC, Dy, and B.

Assignees

• Cui Jun
• Grant Glenn J
• Jana Saumyadeep
• Hovanski Yuri
• Lavender Curt A
• Battelle Memorial Institute

Inventors

• Cui Jun
• Grant Glenn J
• Jana Saumyadeep
• Hovanski Yuri
• Lavender Curt A

Classifications

• B29C2043/3433

  using dispensing heads, e.g. extruders, placed over or apart from the moulds · CPC title

• B29C43/04

  using movable moulds · CPC title

• B29C43/56

  Compression moulding under special conditions, e.g. vacuum · CPC title

• B29C43/361

  with pressing members independently movable of the parts for opening or closing the mould, e.g. movable pistons (transfer moulding B29C45/02; injection-compression moulding B29C45/561) · CPC title

• B29C2043/043

  rotating on their own axis without linear displacement · CPC title